Building construction



Jan. 3, 1939. R. w. MCLAUGHLIN, JR `2,142,523

BUILDING ONSTRUCTION I 4 Sheets-Sheet l Nic:

Filed Sept. 25, 1936 ma l ATTORNEYS Jan- 3, 1939- R. w. MCLAUGHLIN, .1Rl 2,142,523

BUILDING CONSTRUCTION 4 Sheets-Sheet 2 Filed Sept. 25, 1956 I -VENTOR- Jan. 3, 1939. R WMCLAUGHUN, JR 2,142,523

BUILDING CONSTRUCTION Filed Sept. 25, 1956 4 Sheets-Sheet 3 I gg [BY/52M R. w. MICLAUGHLIN, JR 2,142,523

BUILDING CONSTRUCTION Jan. 34, 1939.-

'Filed sept. 25, 193e TTOREY:

Patented Jan. 3, 1939 BUILDING CONSTRUCTION nahen w. mummia, Jr.. New York, N. Y., u-

slgnor to American Houses, Inc., New York,

N. Y., a corporation of Delaware 'Application September 25, 1936, Serial No. 102,451

This invention relates to building construction, and more specifically to prefabricated buildings.

In general, it is an object of the invention to provide a -device of the character described which will eiliciently perform the purposes for which it is intended, which is simple and economical of construction, which can be expeditiously, conveniently and safely manipulated, and which can be readily manufactured and assembled.

Other objects of the invention are to provide a building unit which may be interchangeably used throughout the flooring or the wall or the ceilings or the roof; to provide such units which interlock; to provide a simple keying arrangement for interlocking such units; to provide such units which may be fabricated at the factory and interlockingly assembled at the place where' the building is to be erected, preferably without the use of rivets, nails or the like; to provide such units which may have heat-insulating material added as or before `they are assembled; to provide such units which may be assembledinto 'buildings of various types of room lay-out; and

to provide such units which maybe used as connecting conduits at the same time as units for floor or wall structure.

Another Objectis to provide interchangeable, prefabricated umts which,- when assembled, form a self -supporting structure.

Another Object is to provide a building, the walls of which are, at least in part, suspended from the floor; to provide such a building, the ceilings of which are suspended from the walls;

and to provide interlocking suspending means accomplishing this.

Other objects of the invention will in part be Obvious and will in part appear'hereinafter.

The'invention accordingly comprises an articonnection with the accompanying drawings, in

which: f

Figure 1 is a plan view, in section, of a construction embodying one form of the invention; Fig. 2 is a perspective view, partly in section, of a construction like that shown in Fig. 1, with certain parts removed and certain parts added;

Fig. 3 is a perspective, more detailed view of certain of the elements shown in Fig. 2;

Fig. 4 is a sectional view, in elevation, ofthe elements shown in Fig. 3 and in conjunction with certain other elements normally adjacent thereto and shown in Fig. 2; and .i Fig. 5 is an elevational, sectional view of a ceiling and roof` which may be used in conjunction with the parts shown in Figs. 1 and 2 and which embody one form of the invention.

'I'his invention contemplates a house or other building, the great majority of the parts of which may be manufactured into relatively large-sized units at the factory and 'which may be erected simply by the interlocking of these together at the site of the building, without the use of bolts, rivets, nailsor the like.

A principal unit, as shown in Fig. 1, comprises a panel Ill, which may be of plywood, board Or yl2 which are attached to the panel by any con'- venient means, such as nails or rivets, or' by a suitable adhesive, along the long ledge of the panel. 'I'his trough-like element may be used in the roong where the panel becomes the support for the roof proper. It may be iised in the ceiling. When it is used in the partitions, a second panel element I I may be carried by the stud elements parallel to, and spaced from, the panel I0. The unit may be used as an outer wall, in which case any suitablecovering elements such as brick veneer, metal lathe and stucco. shingles, or ship lap siding i4 with lap siding i6 thereon may be positioned parallel to panel I0 to serve as* the outside of the building. The unit'may be used in constructing a oor. vIn this last in' stance, a panel i I I, which may be of any suitable insulating material, may serve as a protection against the dampness of the ground and may also serve to form the unit into a conduit whereby' other suitable material, and two stud elements 20 hot or cold air,` piping, or wires may becarried about the building'.`

The various units employed in the lbuilding are preferably of the same breadth, and all iloor units are preferably of the same length, as are all wall units and all ceiling units. It is tO be understood that if the units employedare of a width of two feet or less 'it may be desirable in certain parts of the building, as for example where doors frame elements and the like. It is intended,

however, that basically the structural units embodying the present invention, if intended as wall units, may be interchangeably employed anywhere in thewall structure of the building. The same is true of the units intended as floor orx ceiling or partition or roofing units.

It will be understood also that although certain elements vmay be termed studs or joists throughout this specification, these elements are in fact preferably similarly formed stud or beamlike elements of sheet metal. In the claims it is to be understood that the use of the word"stud or the words stud elements" is to be deemed to include elements of this type where employed specifically as studs -or as joists or the like.

The unit is shown in cross-section in Fig. l in an upright wall. The studs i2, which may be o f sheet metal, such as steel, each have a surface attached toa surface of the panel by such means as a rivet screw, or nail I 3 (see Fig. 2), or by any suitable adhesive. Each stud is shaped or bent to provide a concavity i 8, closely adjacent the panel. The stud elements are positioned at the ends of the panel elements, and where the structural units are assembled in adjacent position, with the stud elements of adjacent 4units abutting, these concavities of adjacent stud elements face in the same direction and nest or interlock, one within another, the one extending out over the edge of the panel and the other in from the edge of the panel, as shown in Fig. 1. Each stud element has a second concavity 20 closely adjacent its other end, spaced from and parallel to but facing oppositely from the mst-mentioned concavityin that stud. Immediately beyond the concavityn, i. e., distal from the panel lll, each stud. element ls bent parallel to the panel Ill in a flat portion 22. Each stud element may have a flat portion 2l between the two concavities.

It will be seen that the stud on the right of the central unit at the top of Fig. 1 flts.into the stud element on the left hand edge of the next unit to the right. A locking or keying member 26, preferably also of thin sheet metal, is used to hold the two adjacent studs together. member may be very simple, comprising a fiat surface 28 with ends 30 bent around the fiat ends 22 of the. contacting stud. If desired, the key 2i may be attached to a piece of wood 22 as by a nail or other element 3l before the element is affixed in place. The element 32 may extend the length of the key 26, and may be of any material to which may be screwedV or nailed,l or otherwise attached, the second panel or wall closure' element.

Itis to be understood that the key 28 need not extend the full'length of the stud element. Sections of the key element of shortlength may be aiiixed at the factory to the cooperating element 22, so `that a section of such element with a short key at each end thereof may be provided, or short sections of the key element and its cooperating element 2 2 may be successively positioned one above the other to 'cover the face of the two internesting adjacent stud elements. If desired the secondary panel or wall-covering elements may be prefabricated of such width as to coincide with the width of the structural unit. The wall-covering elements may, for example. be formed as a slab of material of such width as accurately to coincide with each wall panel element.

At the factory, the panel Il is attached to its n twostuds i2. 'Aplurality of-suehunitsaresent to the site of the building, aligned vertically, in the case of a wall, side by' side, with the studs fitting into each other. A locking element 26.

f with attached strip of wood 32, is slipped down so as to lock each unit with the next unit by holding together the two distal partsof the two' f adjacent studs. In the case of an outer wall. the outer wall surface may then be attached to the wooden strips 22 so as-to form a series of hollow, upright compartments. These may be left empty, or may be filled with insulating material such as mineral wool, II.

The foregoing describes the assembly of any series of units generally; The following is a description of the construction of a building having various types of structural units, one forming the floor, one the walls, another the roof, etc.

Fig. 2 shows portions of two walls which meet at right angles and which extend rupward from the floor, which is supported by a peripheral foundation, all as seen from the outside of the building in projection. The actual corner, where the walls meet, has been cut out to show certain details of the floor-.and the keying of the latter to the walls. A foundation 38. is provided on which the ends of a series of interlocking units are laid. These units each have a main panel, here numbered i i0, which forms the floor of the building or room and, if desired, a lower panel, here Ii i, which is a protection against dampness and the like. Jolsts H2 spacedly position the panels in each unit. Attached along the long side of each outer unit is a keying element |38, hereinafter more specically described.

A series of outer-wall units, which have been fabricated at the factory, is now set up with the panels I0 facing inward. The stud elementsl2 which form a part of each of the wall units are longer than the panels i0 by an amount such that when the lower ends of the studs I2 are positioned adjacent the foundation 36, the panels` i0 have their lower edges in registry with or extending only slightly below the oor panels IIB. Keying elements 38 are suitably attached as by rivets 40 to the upright studs i2. The elements 38 are interkeyed with the keying element I2. on the floor unit, the latter supporting the` former. In this way, the entire wall may be supported from the floor. It may also. if desired. be supported in part by the foundation It. Or it may be entirely supported by the foundation and merely keyed to the floor units.

It should here be noted that the keying elements 2B. which are riveted or otherwise amxed to the lower ends of the vertical stud elements of each wall structural unit, and the keying elements M which are similarly aillxed to the upper ends of the same stud elements of the structural wall units, act as braces to provide, with the studs a rigid frame for each wall element.

They thus perform a double function. acting not only as keying elements but also as supporting 'and bracing elements. The same is true of the.

keying elements "|42 associatedwith the iloor -units, which act in cooperation with the joists H2 to provide a rigid, braced steel structure for those units. The ceiling units are similarly de signed and will be apparent hereafter.

Across the end of each floor unit is provided a 'keying element |42 which is attached by wings I to the webbingof the door Joists Il 2. The

keyingv elements may have been aillxed to the l studs by welding or rivets at the' place of manufacture of 4the units... Another series `of vertical units, aligned in a horizontal row, with a kq.

ing element 42 similar to the keying element 38, is set up along the ends of the viioor units and is keyed to, and thereby suspended from,

' the` keying elements |42 of those units.

' an angle.

one adjacent unit being in one wall and the otherv adjacent unit being in the 'other wall. The corner element may also have keying elements which iit into; and may be supported by, the keying elements |38 and |42 of the floor unit which extends into the corner.

Any suitable outer wall covering elements may be amxed to the upright wooden strips 32, to

which are nailed the locking elements 26. Mineral wool 35 may be inserted into the hollow, upright compartments formed by the,upright units and covering elements. that theinsulatingmaterial may, if desired,'be put in place at the factory.

A ceiling is provided as follows (see Fig.

The upright studs |2 of the wall units extend upwardly beyond the inner wall panels Il and have keying elements -44, similar to keying elements 42, suitably attached to them. These are in reversed position vertically as compared with keying elements 42 because the latter areused to support the wall from the floor, while keying elements 44 are used to support the ceiling from the side walls. A series of units is` brought together side by side in a horizontal row so as to forma ceiling. The main panels 3|0 face downward. 'Ihe joists 3|2, associated with these panels, havey keying elements 3 44 similar to the keying elements |42 at the ends of the floor units. They are reversed in position because they are to be suspended from the keying elements 44 at the top ofthe wall units i2. The keys v344 have wings 343 to attach them to the ceiling unit studs 3|2. Along the long side of those ceiling units which are at the edge of the ceiling, there may be provided a keying element, not shown, but corresponding 'to the keying element |33 which extends along the long side of those floor units which are at the edge of the floor, and this ceiling keying unit, not shown, may -be interlocked with, and be supported by, a keying element, not shown, which is horizontal and fixed to the tops of the studs and those wall units which are successively adjacent the long side of the edge unit ofthe ceiling.

Each end of each ceiling ported, as shown for one end only at 344 and 44 inFig. 5. However, there may be a partition in the building with surface panels-||| and separating the interior of the building into rooms. In `such a case, one end of each4 ceiling unit is suspended, as shown at 344 and 44, and-the other one of each ceiling unit may r'eston one of the panels ||l or of the vertical partition unit or on the studding associated therewith. 'A second series of ceiling units having ceiling panels 3|| may be similarly supported from an outer wall, not shown, and rest on partition panel Keying elements 45 and 345 may lkey together the ends of the ceiling units which rest on partition panelsl and respectively. There may not be a second panel parallel to, and above.

It should be noted vunitmay be suppanel ill and carried by the ceiling unit joists 3|2. When the upper panels are lacking, the ceiling lfrom above looks like a plurality of tightly packed troughs. Material 35 may be inserted in these troughs to prevent the transfer of heat.

The keying elements have a central portion extending lengthwise thereof (see Fig. 3). Along one edge there is a U-shaped extension 12, each arm of which is parallel with; butnot in the plane of, the central portion 10. Along the other lengthwise edge of the element, there is a iiat portion 14 parallel with, but not in the plane of, the central portion 1|l.` It will beseen that two such elements may be interkeyed, the por tion 14 of one fitting into the UA-shaped exten.- sion 12 of the other. Whichever one is to support theotherhas its U-shaped extension facing upwardly along its lower edge. Thus, the exten sion of keys |42, |38, 44 and 345 is along the llower edge, while the extension of keys 33, 42, 344 and 45 is along the upper edge.

Attention should bedrawn to the shape of the keying elements. It should be noted that the ,U-shaped extension portion of each element and the ilat portion adapted to internest or interlock with a U-shaped extension portion of a cooperating keying element are displaced forwardly from the plane of the central portion of the keying element. nature and of such extent as to permit the interlocking or interkeying units to be moved intointerlocked position vertically and without lat--` eral displacement of veither unit. If, for exam- -ple, it is desired to remove a single'wall panel unit before the roof .is fixed in position, the unit may be lifted vertically and without lateral displacement until the keying elements are completely disengaged. Elements such as are shown in the drawings and which are designed with both the VU-shaped extension and the fiat extension laterally displaced from the central portion may be adapted to permit such adjustment Without difficulty.

'I'his displacement is of such Roofing also may. be supplied and formed ,from

prefabricated units similar to the other units in l the building, the main panels 4|0 being on the upper side. One series of units may extend slopingly upward from the top of one wall, andan other set from the top of an opposite wall, and be upheld centrally by a keystone element 16.

To this latter, a ridge pole and assoclatedroof- 'r ing devices, not shown, may be attached. 'I'he outer, lower ends of the studs 4| 2 of the roof units are provided with a special form of lkey 444, which sits in, and is held by, a key 35|! attached to the ceiling units. The latter key has a U-shaped extension 35| into which an extension of 'key 444 extends. a bend in key 444. The bend and th U-shaped 'part of key 35u support the outward thrust of the roof transmitted by key' 444;

It will be seen that, the weight of the roof being transmitted diagonally downward and outvward against keys 35|), there is set up an outward, horizontal component of that force to which the ceiling units are subjected and which is transmitted to the wall elements. The keying elements 45 and 345 are therefore subjected to tition elements of at least some ofthe weight of the ceiling elements.

A bend in key 350 abuts a stress. This, in turn,'relieves theinterior parvJoists which form the side walls o f various units, such as the .floor units. may be provided with openings 18. the openings in one Joistl being in registry with the openings of a ioist inthe next unit, so that the units-may intercommuniu cate and act as conduits for the transmission of hot Vor cold air, pipes, etc.

4 It is of course to be understood that while the wall-'forming units have been shown as suspended by the floor units, and while certain other units have been shown as suspended from or supporting still other units, these arrangements may be altered in any desired manner by altering the relative positions of engaging keying elements.

It should also be pointe'd out that the concavities in the .stud elements, positioned as they are in close proximity to the cooperating panel elements,` act to substantially increase the strength of said stud elements, which in general act as beams wherein an accumulation of material at the ends, such as is provided by the said.con cavities, is highly desirable.

Doors, windows, wall-finishing elements and roong elements have not been shown or described, in the interest of clarity. It is to be understood that for all such purposes standard elements may be employed.

It should be noted that the structures described provide a building utilizing only dry materials in such form and condition that they may be assembled, substantially without theuse of i fastening elements, such as bolts, screws, rivets,

nails and the like, b y substantially unskilled labor.

Since certain changes may be made in the above article and different embodiments of the invention could be made without departingfrom the scope thereof, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements ofthe scope of the invention which, as a matter of language, might be said to fall therebetween.

Having described my invention, what I claim' as new and desire to secure by Letters Patent is: l. A building construction unit comprising a panel element, a plurality of sheet metal stud elements aiilxed to the same face of said panel and adjacent opposite edges thereof, each of said stud elements being provided with means forming a surface spaced from said face of said panel and substantially parallel thereto, the portion of each stud element between said surface-forming means and said panel being formed with a plurality of concavities, one adjacent said panel, another adjacent said surface-forming means, and metallic elements affixed to each of said plurality of stud elements and adapted to form therewith a substantially rigid metallic frame for said unit.

2. A building construction unit comprising a panel element, a plurality of sheet metal stud elements aillxed to the same face of said panel and adjacent opposite edges thereof, each oi laid stud elements being provided with means` forming a surface spaced from said face of said panel and substantially parallel thereto, the portion of each stud element between said surfaceforming means and said panel being formed with a plurality of concavities, one adjacent said e1, another adjacent said surface-forming means, and metallic elements positioned substantially parallel to saidpanel and afllxed to each of said plurality of stud elements and adapted to form therewith a substantially rigid 'metallic frame for said. unit.

3. A building construction unit comprising a panel element, a plurality of sheet metal stud elements afiixed to the same face of said panel and adjacent opposite edges thereof, each of said stud elements being provided with means forming a surface spaced from said face of said panel and substantially parallel thereto, the portion of eachl stud element between said surface-forming means and said panel being formed with a plurality of concavities, one adjacent said panel, another adjacent said surface-forming means, and metallic elements affixed to each of said plurality of stud elements and adapted to form therewith a substantially rigid metallic frame for said unit, said metallic elements being provided with keyways and being adapted to interlock with similar elements.

4. A building construction unit comprising a substantially rigid metallic frame, a plurality of substantially parallel elements of said frame comprislng metallic stud-like elements irregularly shaped to internest with similarly shaped elements of -similar units, a plurality of other elements of said frame comprising metallic keying members adapted to interlock with similar mem- -bers of similar units, and a panel element aiiixed to said stud-like elements.

, 5. In combination, a plurality of building construction units each comprising at least a pair of similarly shaped, substantially parallel, me-

tallicstud-like elements having a panel element stud-like elements having a panel element affixed thereto and separated and substantially rigidly positioned by a plurality of metallic keying elements, adjacent stud-like elements of adjacent units being positioned Ato abut and having irregular surfaces adapted to internest with each other, and means to interlock said adjacent. abutting, stud-like elements of adjacent units, said interlocking means having aiiixed thereto means adapted to engage a wall-closing means.

7. In combination, a plurality of building con struction units each comprising a't least a pair of similarly shaped, substantially parallel, metallic stud-like elements having a panel element amxed thereto and separated and substantially rigidly positioned by a plurality of metallic keying A elements, adjacent stud-like elements of adjacent units being positioned to abut and having irregular surfaces adapted to internest with each other, adjacent keying elements of adjacent units being adapted' to .engage and interlock with each other, and means to interlock said adjacent, abutting, stud-like elements of adjacent units.`

8. In a building, in combination, a pluralityvof construction units of substantially equal width and adapted to form a floor, a plurality of wall units of substantially the same Width as said 1 floor units,l and means comprising similarlyshaped elements' affixed to said floor and said wall units for interlocking said wall units with said floor units, said wall units being supported by portions of said oor units other than he upper surface thereof.

ROBERT W. MCLAUGHLIN, Jn. 

